Apparatus for the manufacture of cementitious sheets



Aug. 13, 1935. R DORN r v 2,011,439

APPARATUS FOR THE MANUFACTURE OF CEMENTITIOUS SHEETS Filed April 28,1952 5 Sheets-Sheet 1 w &

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ATTORNEYS Aug. 13, 1935. RODORN .5! AL APPARATUS FOR THE MANUFACTURE OFCEMENTITIOUS SHEETS Filed April 28, 1932 3 Sheets-Sheet 2 lNVEN TORSZena Born BY Afar/1n lVtZltls K @7/ ATTO RN EY$ Aug. 13, 1935. R. BORNET AL APPARATUS FOR THE MANUFACTURE OF CEMENTITIOUS SHEETS Filed April28, 1952 3 Sheets-Sheet 5 a .8 m MW m 7 7 W; m 1

. 3 d y T 5 A m/ 0 m M NM 4 1 m :2 W i w M Q fl 7 a f 4 g Patented Aug.13, 1935 APPARATUS FOR THE MANUFACTURE OF CEMENTITIOUS SHEETS Rene Bornand Martin Willis, New Orleans, La. I Application April 28, 1932, SerialNo. 607,971

14 Claims.

This invention pertains generally to apparatus for theformation ofsheets and particularly to apparatus for the formation of sheets frompulps.

In our copending application Serial No. 607,970, now Patent No.2,004,935, dated June 18, 1935, there is shown and described anovelcementitious sheet and a process for making-the same. The inventionherein relates to apparatus adapted to be used in carrying out .theaforementioned process.

Referring to the drawings in which like reference characters areappended to like parts in the various figures,

Figure 1 is an elevation of apparatus for carrying out theabove-mentioned process;

Figure 2 is a plan view thereof;

Figure 3 is a perspective'view of a matrix showing a layer of pulpthereon;

Figures 4, 5 and 6 are broken sections of finished sheets;

Figure 7 is an elevation partly in section of a hopper and of partsadjacent thereto;

Figure 8 is a plan view of the hopper, and

Figure 9 is a detail of an'adjustable eccentric.

-Referring more particularly to the drawings, at I in Figures 1 and. 2is shown a' conveyor illustrated as being of the driven roller type.However, any other suitable type of conveyor, whether endless or not,may be substituted therefor.

Resting on the conveyor I0 is a matrix I I having an upper surface I2with a shape substantially identical with that of the sheet to bemanufactured.

At I3 is shown a hopper containing pulp I4. Hopper I3 has an opening Itransversely there- 'of of a length'equal to the desired width of thelayer I6 of pulp which is formed by'pulp I4 passing through the openingI5. The hopper shown is of the type more particularly described andclaimed in our co-pending application Serial No. 706,814, now Patent No.2,004,936, dated June 18, 1935.

Pulp I4 may be of a consistency so as to flow by gravity through theopening I5 but is preferably of lesser water content. This will requiresome special means to cause the pulp to flow through the opening I5because of the stifferand viscous consistency. Such means may comprise avibrating hopper, a form of which will be more particularly describedhereinafter or any other suitable device such as one adapted to'extrudethe layer I6 through a die conforming to the desired opening I5 by meansof pressure on the pulp I 4 with or without heat. I v

If the pulp contains a fibre, such as pulp made from hydraulic cement,asbestos fibre and water, the fibre'upon passing through the narrowopening I 5 will become substantially oriented into planes more or lessparallel with the surface of 1 the layer I6'formed by the opening I5. Wefind substantial orientation is obtained with layers up to threequarters inch in thickness.

The matrix I I is positioned and moved relative to the layer I6 so thatthe'end of layer I6 contacts the right end of matrix I I, as'seen inFigure 1, the matrix II preferably moving to the'right on conveyor ID ata speedconforming more or less closely to the speed at which the layerI6 issues from the opening I5 so that the layer I6 will be laid out onthe matrix II without undue stretching or buckling.

The layer I6 will conform to the surface I2 of matrix II whether suchsurface I2 is fiat, corrugated or of any other configuration, formingthereon a sheet layer of substantially uniform cross sectional thicknessthroughout.

Depending upon thetype of means employed for depositing layer I6, thislayer may have a certain slight surface unevenness or waviness.

To remove any such irregularity, we may provide a roller I8 adapted tolightly touch the upper surface of the layer I6 throughout its width,the roller l8having a contour conforming to that of the layer I6. Theroller I8 preferably is driven so that its surface moves oppositely tothat of the layer I6 and at a substantially greater speed. The roller I8 is essentially a smoothing roller and its contact with the layer Ifishould not be such as to cause pulp to accumulate on the front side ofthe roller. I8.

Any other means might be substituted. for the roller I8 such as a shoeadapted to lightly contact the upper surface of the layer I6. I g

It might be pointed out here that itis not necessary to expel any waterfrom the layer I6 at this point. Expelling of water is accomplished bymeans of a press 25 having an upper matrix or die 26 conforming to theupper surface 1 of the layer I 6 anda lower matrix or die 2'l'for.

holding the matrix II. To expel watenmatrix 21 together with the matrixH and the sheet thereon are raised by means of the piston and cylinderarrangement shown at 30,'the upper sur- "face of the layer I6 coming incontact. with the matrix 26 and being substantially uniformly contactedthereby throughout its surface so that the water is expelled withoutsubstantially disturbing the previous structural'relationship of thesheet l6 or substantially displacing the par.-

the manufacture of laminated sheets, it being merely necessarytoduplicate the hopper l3, as

illustrated at 2|, or to add any additional number offhoppers dependingupon the number of laminations desired. As shown, the roller l8 has beenduplicated at 23.

Any additional layers such as the layer 20 posited upon layers IE willconform to thereon-j figuration of the layer IS in all respectssimilarly to the manner in which the layer l6 has con;

formedto the matrix II. Due to the semi-fluid character of the layers ofpulp and'the care-with which the second layer is deposited upon thefirst, there may be a slight and inconsequential shift of material sothat one layer might'be very slightly thicker at one pointth'an atanother. However,

"such slight shift in material is wholly incidental and in' no waydepartsfrom the spirit of the invention. a r

Orientation of the fibres greatly increases the tensile strengthof thelayer per unit of fibre content. a

' By variation of fibre "content in each layer the tensile strengthacrossa sectionof a sheet may be varled in accordance withdemands. Forinstance; if the load is'on one face of thesheet the layer adjacent the.load will be under compression'and the layer opposite the load will beunder tension. The layer under compresion may, thereforefhave'less'fibre in View of the higher compressive strength of materials of thistype; This will increase its resistanceto the elements.

It is very'simple to provide. means for .study- ,ing the division linebetween theadhering laminations by merely providing any suitable devicesuch as illustrated at H! for depositing-a thin filmoistfipesof coloringmatter ll on the layer I6.before'applicationof the layer 20 thereto; We

find that avery suitable coloring substance can be madeby mixing 90% dryhydraulic cement and -10% red'iron oxide. It is, of course, understood:that any other substance might be substituted z'the'refor inasmuch'asthe function of this coloring matter is merely to show. the .divisionline between the adhering laminations to identify the -processby meansof which the sheet hasbeen manufactured; If: more than two laminationscomprisethe'sheet, it is,. of course, understood that, if desired, any,additional number of color depositing devices may be added.

The manufacture of sheets by means ofv com .bining'laminationsaffords anopportunity to efficiently incorporate reinforcement members during the:steps .of superimposing the layers. For, instance, in the manufactureof corru- "gated sheetspparticularly those used for roofing I purposeswherein the ,vales are placed under ten- :sion and the crests undercompression, inasmuchas the compressive strength of this type ofmateirlalif is substantially greater than the! tensile strength it isdesirable .to reinforce the Vales;

.This may be done by; laying longitudinalrodsin the vales between thehoppers|3 and 2I-. -These longitudinal rods, of course, arelnotreshapedin thepress but already they-.wil1'have in the finished product.ItjiS,:Qf course, possible to also insert rods inthe crests ifj-desiredior insert rods in the, crests only lt is R also possible .toemploy any, other,formg,of' rein- The reduction inv forcing, member 46.

shafts 56 and 51.

have theshape which ,Q Shaft 51- is journaled in forcement alone or inaddition to the rodssuch are examples. Such mesh would be preformed toconform to the upper surface of the layer I6 '50 that no reshaping wouldbe necessary in the press 25 or otherwise. For instance, if the sheet.

is to be corrugated, the mesh would also be corrugated.

After the desired number-of. laminations have been superimposed withlorwithout coloring mat- ,ter and/or reinforcements, the composite massis-placed within the press 25 and the water ex npe lled in the samemanner as above set forth.

3 'Ihe'matri-x I I is then' withdrawn and the sheet is strippedtherefrom or permitted to cure on the matrix as desired,

While the invention has been described in connection with a singlematrix, it is, of course, un-

derstood that the matrices II will succeed each other on the conveyorIn. In fact, the matrices I I may be arranged on the conveyor II] withabutting ends so that the layers of pulp may be 'depositedcontinuously,-the cutting of the layers between the matrices takingplace justbefore introduction of each matrixinto=the press 25.

Other means may be substituted for the press 25for expelling water fromthe sheets.

may be substituted. It willbe seen-that the layer 3| has conformedto'the corrugations.

In Figure 4 we have shown a sheet 32'corn-' prising upperlaminatio'n 33and lower lamination 34. The line35 shows the colored dividing linebetween the layers 33 and 34,1the inclusion; of:

which is, of course, optional.

In Figure 5 we have .shown a sheet 3ljcompri'sing'upper lamination 38an'dilower lamination 39.

40 is the dividing line between the two laminations. "At- 4| .we:.-haveshownirodspositioned. in

the Vales between laminations138'and'39 for reinforcement purposes. Itis, .aof course, understood that 'thelamina- .tions join into; a unitarysheetv and strongly adhereto the reinforcing members 4|. i

.. -In Figured we haveshown a sheet com- .prisingupper lamination 44 andlower laminationj45. We have alsoshown a corrugatedr'eticularreinforcing member 46 positioned between the laminations 44 and '45.The; laminations, of

course, adhere ,to each other.

, and to the rein- In Figures 7 and 8 we have shown a vibrating hopper.-.Thi'sfl hopper comprises" oppositely arranged reciprocating sidewalls50 and 5|;shown ,arran'gedin the form of a V with an opening 52at;thejvertex. Side walls 50 and 5l areshown arranged between stationaryend walls 53, the

,side walls 50 and 5|, being-supportedin guides 51 securedto the endwalls 53.;

Mounted on the frame i4;9 ;ar'e two transverse Shaft55is shown drivenbya motor 58 through reduction gearing 59 and belt or chain 60; Shaft 5]isillustrated as driven from shaft 56. by means offachain 6 v A Shaft 56isjournaled -'in slidable blocks 62 blocks 52 being adjustable by meansofgscrews-fit to move the'side; wall with respectto theside wall SI-toadjustthe opening52.

blocks 65, being, ad-

justablebymeansof screws 56 for the purpose of moving side wall 5! withrespect toside wall 50 to adjust the opening 52.

' Side wall 50 is mounted'on spaced eccentrics shaft 51.

i6] ina manner so that the eccentrics 61. recipro- ,wall 5| by means ofvadjusting chain 6| on sprocket 'H on shaft 56 and on sprocket 12 on Theadjustment is preferable one in which side walls 55 and 5| reciprocatein unison, that is, synchronously. It is, of-,course,xunderstood thatthe length of chain 6| will vary ac- ;cording to the adjustment at 63and 66.

The variation in size of the opening 52 and the movement of the sidewalls 55 and 5| about the opening 52, due tothe reciprocationofsidewalls 55; and 5| not only causes the pulp 13 to flow through theopening 52 in layer form but also tends to cause any fibre in the pulpto become oriented into planes substantially parallel to the surfaces ofthe layer of pulp formedat the opening 52. 1

As shown, the opening 52 has a longitudinal dimension more or less equalto the Width of the matrix H.

The cross sectional contour of the layer of pulp may be varied byvariation in the lower edge of side wall 5| and/or side wall 55. Thiswill prove of advantage in forming corrugated sheets with thickenedcrests and vales such as described and claimed in copending applicationSerial No. 447,150 of Martin Willis and Frederick Schroder.

Side wall so in Figure 7 is illustrated as being somewhat longer thanthe side Wall 5| at the opening 52. The side wall 59 thus acts somewhatas abase toward which the side Wall 5| may operate in the formation of alayer, both side walls acting to advance the layers through the opening52: However, any other arrangement of the ends of side walls 55 and 55may be made.

The layer I 6, issuing from the opening 52, may be more or lessundulatory in character in a lengthwise direction. If desired, a roller15 may be provided for smoothing the layer it. The action of roller 75is merely smoothing in character and roller '55 ordinarily will no morethan lightly touch the surface of the layer 6. Roller 75 preferablyrotates in a direction opposite to the movement of the layer it onmatrix H and should preferably have a somewhat increased peripheralspeed. Roller 75 may be made adjustable vertically by means of screwsIt.

The chute, shown at H, pertains to a device for keeping the pulp l3 at auniform height in the hopper and otherwise does not pertain to thisinvention.

Another means for timing the reciprocation of a side wall 55 withrespect to the reciprocation of side wall 5| is by use of an adjustablecam. Such a cam, however, is more useful for varying the length of thestroke of the reciprocating side walls. One form of adjustable cam isdisclosed in Figure 9 in which an eccentric rim portion T8 is madeadjustable with respectto an'eccentric hub portion 19 mounted on a shaft863. The adjustment may be accomplished by providing the hub portion 19with a plurality of spaced grooves 8| which are adapted to cooperatewith a complementary groove 82 in the rim portion F8 to form a key-wayfor a key 83. It is, of course, understood that any other form ofadjustable cam may be employed. By moving rim portion '58 with respectto hub portion 79 the length of the stroke of the side wall may bevaried as will be understood by persons skilled in the art. Anynecessary adjustment as to synchronization may then be made by adjustingchain 6|.

It is, of course, understood that any other means maybe employed fordriving shafts 56 and 57 and for connecting the shafts together so as tosynchronize the movements of side walls 50 and 5|.

The particular description herein has been merely for the purposes ofillustration and many modifications and/or substitutions may be made inthe parts particularly described without departing from the spirit ofthe invention. The claims herein are intended to be limited only by theprior art.

1. Apparatus for forming a sheet from pulp comprising a rigid matrixhaving the contour and extent of the finished sheet, and meansindependent of said matrix for forming pulp into a layer and applyingsaid layer upon said matrix.

2. Apparatus for forming a sheet from: pulp comprising a matrix in theform of the finished sheet movable in a substantially horizontaldirection having an operative surface of corrugated contour, andmeansfor depositing a corrugated layer of pulp upon said matrix as saidmatrix moves past said means.

3. Apparatus for forming a sheet from pulp comprising a rigid matrixhaving the contour and extent of the finished sheet and having anoperative surface conforming to the desired shape of the sheet, andmeans independent of said matrix for forming pulp into a layer anddepositing said layer upon said matrix.

4. Apparatus for forming a laminated sheet comprising a formed matrixhaving a contour conforming to the desired shape of the sheet, meansindependent of said matrix for forming pulp into a layer and depositingsaid layer upon said matrix, and means for similarly depositing a secondlayer of pulp upon said first layer.

5. Apparatus for forming a laminated sheet comprising a formed matrixhaving a contour and means for moving said matrix relative to saidhopper.

7. Apparatus for forming a laminated sheet comprising a formed matrixhaving the contour and extent of the finished sheet, a plurality ofspaced hoppers, means for moving said matrix consecutively under saidhoppers, said hoppers adapted to successively issue layers of pulptherefrom and deposit it upon said matrix.

8. Apparatus for forming a laminated sheet,

comprising a rigid matrix, means independent of said matrix for formingpulp into a layer and depositing said layer upon said matrix, and meansfor smoothing the surface of said layer.

9. Apparatus for forming a sheet comprising a corrugated perforatedmatrix movable in a substantially horizontal direction, and means fordepositing a corrugated'layer of pulp upon said matrix as said matrixmoves past said means.

IO/Apparatus for forming a sheet comprising a rigid formed matrix havingthe-contour and extent of the finished sheet, said matrix also having anupper surface of a shape desired in the sheet, means independent ofsaid'matri'x for forming pulp into a layer and depositing said layerupon said matrix, and a press having a matrix of a shape desired in thesheetv and adapted to receive said first mentioned matrix thereon andsubstantially uniformly compress said layer to express water therefromand to consolidate said layer.

' l1. Apparatus for forminga laminated sheet comprising a rigid formedmatrix having the contour and extent of the finished sheet, said matrixalso having an upper surface of a shapedesired in the sheet, meansindependent of said matrix for forming pulp into a plurality of'l'ayersand superimposing said layers upon said matrix, and

a press having a matrix of a shape desired in the sheet and-adapted toreceive said 'first mentioned matrix thereon and substantially uniformlycompress said superimposed layers to consolidate said layers and expressWater therefrom.

express water therefrom.

construction-having the contour and extent of the finished sheet andalso having an operative surface of a shape desired in the sheet, meansindependent of said matrix' for forming pulp into a pluralityof'layers'and superimposing said layers upon said matrix, and a presshaving a matrix of a shape desired in the sheet and adapted to receivesaid first mentioned matrix thereon and substantially uniformly compresssaid superimposed layers to consolidate said layers "and -14. Apparatusfor forming a laminated sheet comprising a rigid formed matrix offilter-bed construction having the contour and extent of the'fi'nishe'dsheet and-also having an operative surface, of a shape desired in thesheet,- means independent of said matrix for forming pulp into "aplurality of layers and. superimposing said layers upon said matrix,means for depositing coloring matter on said pulp and a press having amatrix with an operative surface of the shape desired in'the sheet, saidlast mentionedsurface adapted to receive said first named matrix thereonand cooperate with said first mentioned surface to substantiallyuniformly compress said superimposed layers to consolidate said layersand express water therefrom.

- NE N: V

MARTIN WILLIS.

